Stator for a vehicular rotary electric machine and a manufacturing method thereof

ABSTRACT

To secure insulation between electrical conductors at a coil end, a first electrical conductor at one coil end is arranged so as to intersect a radially adjacent second electrical conductor at one point or more. The electrical conductor is formed with radial indentations in side faces that are opposite side faces in opposing electrical conductors at any of the intersecting portions, the indentations having depths that increase toward the near ear of the electrical conductors. Sufficient clearances are thereby secured between electrical conductors in their intersecting portions near their ends where the insulating films are susceptible to damage because of welding heat. Electrical insulation is thus ensured, and the cooling efficiency at the coil end is improved.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is based upon, claims the benefit of priority of, andincorporates by reference the contents of prior Japanese PatentApplication No. 2002-9861 filed Jan. 18, 2002.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a vehicular rotary electric machine,such as an AC generator for example, that is mountable on cars andtrucks.

2. Description of Related Art

Generally, many cars are being designed with slanting hoods to minimizeaerodynamic drag. Additionally, cars are also being designed withsmaller engine compartments in order to provide greater interior space.As a result, there is increasingly less space available for mounting ACgenerators within the vehicle engine compartments. Meanwhile,increasingly lower engine revolutions (rpm) achieve increasingly betterfuel economy, but reducing engine rpm also reduces the rpm of thevehicular AC generator. On the other hand, the need for increasinglyhigher power outputs of vehicular AC generators are increasingly greaterbecause of the increased electrical loads created by controllers ofsafety features and other electrical loads. Thus a small high-power andlow-cost vehicular AC generator is in great demand.

Another problem is that fan noise and magnetic noise of a supplementarymachine such as the vehicular AC generator, which is driven at arelatively high speed, has become more and more bothersome. This isbecause engine noises have been greatly reduced in recent years inresponse to social demands for less traffic noise and in order toenhance commercial value of cars by making the interiors more quiet. Atypical stator winding used in a conventional vehicular AC generatoradopts a structure in which continuous wires are wound around a statorcore. Additionally, various improvements to the stator windings havebeen proposed to meet the above-described demands of compactness, highpower output, and low noise.

For example, Japanese Patent Laid-Open Publication No. Sho 54-66406discloses inserting a collective winding successively into the slots ofthe stator from outer layers, so as to prevent the stator winding fromcrossing at one coil end and becoming long. With this structure,however, although the wires do not cross each other at one coil end asthey are inserted from outer layers towards inner layers of the slots insuccession, there arises another problem in that there is a dead spacewithin the slots since the outer layers of the winding are arranged onthe outer side and the inner layers on the inner side in the slots. Onthe other hand, an attempt to fill the slots with coils so as not toleave any dead space would result in the wire layers crossing each otherbetween the inside of the slots and the coil end.

To overcome the problem of intersection of the winding at the coil endand within the slots, Japanese Patent No. 2927288 proposes a techniquewhich adopts a stator winding constructed of a plurality of conductorsegments in order to increase the space filling factor of the statorwinding within the slots and to ensure high cooling efficiency on theoutside of the slots by cooperation with the rotor. With this structure,the ends of a plurality of conductor segments are bonded together bywelding to form a stator winding. The bond areas are therefore heated toa high temperature during the welding, and so is the vicinity of thebond areas because of the heat conduction. As a result, the insulationfilms near the bond areas become deteriorated by the heat stress, andthe lessened adhesion of the films to the conductors result in peelingand cracking in the films. Conductor segments with peeled or crackedinsulation film may cross each other and cause short circuits, sincethey are in close proximity to each other. Car vibrations and the likecan also bring about short-circuiting across the conductor segments atthe coil end near the bond areas because the insulation film may becomedamaged by friction or mechanical shock due to the contact.

In view of these problems, the applicant of the present invention hasproposed, in Japanese Patent Laid-Open Publication No. 2000-166148, atechnique to provide clearances between the conductor segments thatradially adjoin and intersect each other at the coil end by formingradial indentations in the conductor segments at the intersectingpoints. The cross-sectional area of the conductor segment remainsunchanged even in the indentation, since the corner radius of therectangular cross section of the conductor segment is large enough toabsorb the displacement of material when forming the indentation bypressing. In other words, the clearance provided by the formation of theindentation is defined by the corner radius of the rectangular crosssection and the width of the conductor segment.

However, the design disclosed in Japanese Patent Laid-Open PublicationNo. 2000-166148 has the problem that, under the condition that thecross-sectional area of the conductor segment should remain the samebefore and after the formation of the indentation, the size of theindentation (or the depth of the indentation) becomes smaller inproportion to a decrease in the corner radius of the rectangular crosssection, or to an increase in the width, of the conductor segment. Ifthe clearances are not sufficiently large between crossing conductorsegments, the insulation film may become particularly susceptible todamage by the friction or the mechanical shock due to the contact whichmay cause short-circuiting to occur.

SUMMARY OF THE INVENTION

In view of the problems encountered in the prior designs, it is anobject of the present invention to provide a stator for a vehicularrotary electric machine and its manufacturing method, in whichsufficient clearances are provided in intersecting portions ofelectrical conductors at one coil end so as to ensure electricalinsulation and to improve the cooling efficiency at the coil end.

In order to achieve the above object, a stator for a vehicular rotaryelectric machine in a first aspect of the invention includes: a statorcore having a plurality of slots and a multi-phase stator windingconstructed of a plurality of electrical conductors connected together.The electrical conductors are accommodated radially side-by-side withinthe slots and are electrically insulated from each other. The electricalconductors have their ends extending to the outside of the slots and arebonded together to form a coil end. A first electrical conductor at thecoil end is arranged to intersect a second electrical conductor at onepoint or more, while the second electrical conductor adjoins the firstelectrical conductor in a radial direction. A radial indentation isformed in a side face of the first electrical conductor opposite to thesecond electrical conductor at least at one intersecting point betweenthe adjacent electrical conductors. The indentation has a depth thatincreases towards one end of the first electrical conductor.

The end portion of the first electrical conductor which will be bondedto the second, adjacent electrical conductor is susceptible toinsulation film troubles such as peeling and cracking because of theheat of welding. However, since the indentation is formed in the sideface of the first electrical conductor opposite to the second electricalconductor at the intersecting point, and the indentation has a depthgradually increasing towards the end thereof, sufficient clearances aresecured between the electrical conductors at their intersecting portionnear the ends. Electrical insulation is thereby ensured, and the coolingefficiency at the coil end is improved.

A stator for a vehicular rotary electric machine according to a secondaspect of the invention includes a stator core having a plurality ofslots and a multi-phase stator winding constructed of a plurality ofelectrical conductors connected together. The electrical conductorsbeing accommodated radially side-by-side within the slots andelectrically insulated from each other. Additionally, they have theirends extend to the outside of the slots and are bonded together to forma coil end, such that a first electrical conductor at the coil end isarranged to be mounted in the stator core in a twisted condition and tointersect a second electrical conductor at one point or more in itstwisted portion. The second electrical conductor adjoins the firstelectrical conductor in a radial direction, and a radial indentation isformed in a side face of the first electrical conductor opposite to thesecond electrical conductor at any of the intersecting points.

The first electrical conductor is mounted in the stator core in atwisted condition at the coil end and intersects the second radiallyadjacent electrical conductor at one point or more in its twistedportion. The radial indentation is formed in the side face of the firstelectrical conductor opposite to the second electrical conductor at theintersecting point. Even when the first electrical conductor is twisted,its radial thickness is kept small. Therefore, a sufficient clearance issecured between the electrical conductors which ensures electricalinsulation and improves cooling efficiency at the coil end.

The stator for a vehicular rotary electric machine according to a thirdaspect has a side face of the first electrical conductor and a side faceof the second electrical conductor that face each other in a skewedattitude at the intersecting point. The radial indentation is providedin the skewed opposing side face of the electrical conductor.

The radial indentation is provided in the skewed opposing side face ofthe electrical conductor taking account of the fact that the side faceof the first electrical conductor and the side face of the secondelectrical conductor face each other in a skewed attitude. Therefore,even when the one electrical conductor is twisted, its radial thicknessis kept small. Accordingly, a sufficient clearance is secured betweenelectrical conductors, whereby electrical insulation is ensured, and thecooling efficiency at the coil end is improved.

The stator for a vehicular rotary electric machine according to a fourthaspect has a twisted portion that is twisted back in an oppositedirection at the intersecting point so that the side face of the firstelectrical conductor is faced in substantially parallel to the side faceof the second electrical conductor. The radial indentation is thenprovided in the parallel opposite side faces of the electricalconductor.

So the twisted portion of the electrical conductor is twisted back inthe opposite direction so that the side face of the one electricalconductor is faced substantially parallel to the side face of the otherelectrical conductor. The radial indentation is provided in theopposite, parallel side face of the electrical conductor. Accordingly,even when one electrical conductor is twisted, its radial thickness iskept small. Therefore, a sufficient clearance is secured betweenelectrical conductors, which ensures electrical insulation, and thecooling efficiency at the coil end is improved.

A stator for a vehicular rotary electric machine according to a fifthaspect includes a stator core having a plurality of slots and amulti-phase stator winding constructed of a plurality of electricalconductors connected together. The electrical conductors areaccommodated radially side-by-side within the slots and are electricallyinsulated from each other. They have their ends extending to the outsideof the slots and are bonded together to form a coil end such that afirst electrical conductor at the coil end has a bond area at its end tobe bonded to a second electrical conductor. The second electricalconductor adjoins the first electrical conductor in a radial direction.The bond area is provided with a protrusion that protrudes towards abond area of the other electrical conductor.

Since the first electrical conductor at the coil end has a bond area atits end to be bonded to the second electrical conductor which radiallyadjacent thereto, and the end is provided with a protrusion thatprotrudes toward a bond area of the second electrical conductor. Theother portions of the first electrical conductor are kept apart from thesecond electrical conductor other than the end to be bonded to thesecond electrical conductor to provide a sufficient clearancetherebetween. Electrical insulation is thereby ensured, and the coolingefficiency at the coil end is improved.

The stator for a vehicular rotary electric machine according to a sixthaspect has the protrusion formed by offsetting the end towards the bondarea of the second electrical conductor. Since the protrusion is formedby offsetting the end of the first electrical conductor toward the bondarea of the second electrical conductor by pressing or the like, the endof electrical conductor is brought closer to the bond area of the otherelectrical conductor, while the other parts of the electrical conductorsother than the end are kept apart from the second electrical conductor.

The stator for a vehicular rotary electric machine according to aseventh aspect has the protrusion formed by bending the end towards thebond area of the other electrical conductor.

Since the protrusion is formed by bending the end of the firstelectrical conductor toward the bond area of the second electricalconductor by pressing or the like, the end of the first electricalconductor is brought closer to the bond area of the second electricalconductor, while the other parts of the electrical conductors other thanthe end are kept apart from the second electrical conductor.

A stator for a vehicular rotary electric machine according to an eighthaspect includes a stator core having a plurality of slots and amulti-phase stator winding constructed of a plurality of electricalconductors connected together. The electrical conductors areaccommodated radially side-by-side within the slots and are electricallyinsulated from each other, and they have their ends extending to theoutside of the slots and are bonded together to form a coil end.Additionally, a first electrical conductor accommodated in at least onelayer of the slots is formed with a protrusion at its end that includesa bond area to be bonded to a second radially adjacent electricalconductor at the coil end. Another electrical conductor is accommodatedin at least one of the other layers in the slots and intersects otherradially adjacent electrical conductors at the coil end at one point ormore and is formed with a radial indentation in its side face oppositeto other electrical conductors at any intersecting portions.

A first electrical conductor accommodated in at least one layer in theslots is formed with a protrusion at its end that includes a bond areato be bonded to a second radially adjacent electrical conductor at thecoil end. The protrusion that protrudes towards the bond area of thesecond electrical conductor is kept apart from the second electricalconductor, except its end which will be bonded to the second electricalconductor, so as to provide a sufficient clearance therebetween.Electrical insulation is thereby ensured, and the cooling efficiency atthe coil end is improved.

On the other hand, a first electrical conductor accommodated in at leastone of the other layers in the slots intersects a second radiallyadjacent electrical conductor at the coil end at one point or more andis formed with a radial indentation in its side face opposite to thesecond electrical conductor at any of its intersecting portions.Therefore, a sufficient clearance is provided between the electricalconductors in the intersecting portion. Electrical insulation is therebyensured, and the cooling efficiency at the coil end is improved.

The stator for a vehicular rotary electric machine according to a ninthaspect has at least one layer that is either an innermost or anoutermost layer in the slots, and the at least one of the other layersis a layer other than the innermost and the outermost layers in theslots.

So one electrical conductor in the innermost or outermost layer of theslots is formed with, at its end, a protrusion protruding towards asecond electrical conductor but with no indentations. Indentations causethe edges of the electrical conductor to become sharper. Therefore,there is no risk of electrical conductors being caught in the insulationmaterial and becoming bent when being inserted into the slots. They canthus be smoothly inserted into the slots.

According to a manufacturing method of a stator for a vehicular rotaryelectric machine according to a tenth aspect, the stator includes astator core having a plurality of slots, and a multi-phase statorwinding. The stator is constructed of a plurality of electricalconductors connected together. The electrical conductors areaccommodated radially side-by-side within the slots and are electricallyinsulated from each other, and have their ends extending to the outsideof the slots and are bonded together to form a coil end.

The manufacturing method of this stator has the following steps: a stepof forming an indentation in the radial direction in a side face of eachof the electrical conductors by pressing; a step of inserting theplurality of electrical conductors in a radially side-by-siderelationship with each other in the slots; a step of bending each of theelectrical conductors and radially adjacent electrical conductors indifferent circumferential directions by a predetermined pole pitch suchthat the indentations formed in respective side faces of the adjacentelectrical conductors intersect each other in a face-to-facerelationship; and a step of bonding one end of each of the electricalconductors to one end of the adjacent electrical conductors.

Therefore, in the indentation-forming step, indentations are formed in aradial direction in side faces of each of the electrical conductors bypressing. In the insertion step, the plurality of electrical conductorsare inserted in the slots in a radially side-by-side relationship witheach other. In the bending step, each of the electrical conductors andradially adjacent electrical conductors are bent in differentcircumferential directions by a predetermined pole pitch such that theindentations formed in respective side faces of the adjacent electricalconductors intersect and face each other. In the bonding step, one endof each of the electrical conductors is bonded to one end of theadjacent electrical conductors. Therefore, radially adjoining electricalconductors are formed with indentations in their side faces such thatthese indentations cross each other in a face-to-face relationship.Therefore, the radial thickness of the electrical conductors at theirintersecting portions is made smaller, whereby clearances betweenelectrical conductors are readily and reliably secured.

The manufacturing method of a stator for a vehicular rotary electricmachine according to an eleventh aspect has indentations that areprovided by pressing such that their depth increases towards one end ofthe electrical conductors.

The end portion of a first electrical conductor at a coil end which isbonded to a second electrical conductor is particularly susceptible toinsulation film troubles because of the heat of welding. However, sincethe indentation formed in the first electrical conductor has a depththat gradually increases towards the end, a sufficient clearance issecured between the electrical conductors in the intersecting portionnear the ends. Electrical insulation is thereby ensured, and the coolingefficiency at the coil end is improved. Also, even when the electricalconductor has a small radius in the corners of the rectangular crosssection, or even when the conductor segment has a large width, theindentation is readily and reliably secured with a sufficient depth nearthe end of the electrical conductor.

The manufacturing method of a stator for a vehicular rotary electricmachine according to a twelfth aspect has, in the bending step,electrical conductors that are clamped at their ends and bent so as tobe twisted. The bending step includes an additional step of twistingback the electrical conductors in an opposite direction at theintersecting point between the radially adjacent electrical conductorsso that the indentations face the indentations of the radially adjacentelectrical conductors in a substantially parallel face-to-facerelationship with each other.

Therefore, even when the electrical conductors are twisted, the opposingindentations are, made substantially parallel to each other by beingtwisted back in the intersecting portions. Accordingly, the radialthickness is kept small, and sufficient clearances are secured betweenelectrical conductors at their intersecting portions.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a vehicular AC generator accordingto a first embodiment of the present invention;

FIG. 2 is a partial cross-sectional view of a stator in a firstembodiment;

FIG. 3 is a schematic perspective view of a segment in the firstembodiment.

FIG. 4 is a perspective view of a second coil-end group side of thefirst embodiment;

FIG. 5 is a side view of the second coil-end group of the firstembodiment viewed from the inside of the stator;

FIG. 6 is a plan view of a segment used in the first embodiment;

FIG. 7A is a diagram showing how to form an indentation by pressing;

FIG. 7B is an enlarged view illustrating the indentation in the vicinityof the end of the segment of FIG. 6;

FIG. 8 is a plan view of a segment in the prior art;

FIG. 9 is an enlarged view illustrating the indentation in the vicinityof the end of the segment of FIG. 8;

FIG. 10 is a cross-sectional view taken along the line 11 a-11 a of FIG.9 in superposed relation with a cross section taken along the line 11b-11 b of FIG. 9;

FIG. 11A is a cross-sectional view of a segment before being formed withan indentation;

FIG. 11B is a cross-sectional view of the segment of FIG. 11A after anindentation has been formed;

FIG. 12A is a cross-sectional view of a segment with a smaller cornerradius that FIG. 11A before being formed with an indentation;

FIG. 12B is a cross-sectional view of the segment of FIG. 12A after anindentation has been formed;

FIG. 13A is a cross-sectional view of a segment with a larger width thanthe segment of FIG. 12A before being formed with an indentation;

FIG. 13B is a cross-sectional view of the segment of FIG. 13A after anindentation has been formed;

FIG. 14 is a side view of the second coil-end group of the firstembodiment viewed from the inside of the stator;

FIG. 15 is a schematic perspective view of large and small segmentsinserted in the slots of the stator;

FIG. 16 is a schematic perspective view of large and small segmentsinserted in the slots of the stator, each of them being bent inrespective circumferential directions;

FIG. 17 is a schematic view of the segments viewed from their ends forillustrating their bending directions;

FIG. 18 is a cross-sectional view of intersecting portions of prior artsegments which have no indentations and are twisted;

FIG. 19 is a cross-sectional view of intersecting portions of prior artsegments which have indentations and are not twisted;

FIG. 20 is a cross-sectional view of intersecting portions of prior artsegments which have indentations and are twisted;

FIG. 21 is a cross-sectional view of intersecting portions of segmentsof a second embodiment of the present invention which have indentationsand are twisted;

FIG. 22 is a plan view of a segment used in the second embodiment of thepresent invention;

FIG. 23 is a cross-sectional view of the segment taken along line 23-23of FIG. 22;

FIG. 24 is a cross-sectional view of the segment taken along line 24-24of FIG. 22;

FIG. 25 is a cross-sectional view, corresponding to FIG. 24, of amodified example of the second embodiment of the present invention;

FIG. 26 is a plan view of a segment used in a third embodiment of thepresent invention;

FIG. 27 is an enlarged view illustrating the vicinity of the end of thesegment of FIG. 26;

FIG. 28 is a cross-sectional view of the segment taken along the line28-28 of FIG. 26;

FIG. 29 is a cross-sectional view of the segment taken along the line29-29 of FIG. 26;

FIG. 30A is a diagram illustrating how to press form a protrusion in amodified example of the third embodiment of the present invention;

FIG. 30B is a diagram illustrating a view showing the vicinity of theend of the segment after bending;

FIG. 31 is a partial cross-sectional view of a stator according toanother embodiment of the present invention; and

FIG. 32 is an enlarged view of area T of FIG. 31.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Various embodiments of a stator for a vehicular rotary electric machineand its manufacturing method, when applied to a vehicular AC generator,will be described with reference to the drawings.

First Embodiment

FIGS. 1 through 7 illustrate a first embodiment of the presentinvention, FIG. 1 is a cross-sectional view of major parts of avehicular AC generator and FIGS. 2 through 7 are explanatory diagrams ofthe stator in this embodiment.

Vehicular AC generator 1 includes a stator 2 that functions as anarmature, a rotor 3 as a field coil, a front housing 4 a and a rearhousing 4 b supporting the rotor 3 and fixing the stator 2 from bothsides with fastening bolts 4 c, and rectifiers 5 for converting AC powerinto DC power. The rotor 3 rotates integrally with a shaft 6 andincludes Lundell-type pole cores 7, field coils 8, slip rings 9 and 10,and an air blowing system including a diagonal current fan 11 and acentrifugal fan 12. The shaft 6 is joined to a pulley 20 and is rotatedby an engine (not shown) mounted on the vehicle.

A typical Lundell-type pole core 7 has a pair of pole cores. TheLundell-type pole core 7 includes a boss 71 assembled to the shaft 6,disks 72 extending radially from both ends of the boss 71, and twelveclaw poles 73. The diagonal current fan 11 on the side of the pulleyrotates integrally with the rotor 3, and has blades on a base plate 111fixed to the end face of the pole core 7 by welding or the like. Some ofthese blades are arranged at an acute angle, while the others are atright angles, to the base plate 111. The centrifugal fan 12 on theopposite side of the pulley includes a base plate 121 fixed to the endface of the pole core 7 by welding or the like and blades arranged atright angles to the base plate.

The housing 4 a, 4 b includes air inlets 41 in one axial end facethereof. On both sides in the outer circumferential surface of thehousing 4 a, 4 b are provided air outlets 42, which discharge coolingair, that are respectively positioned on the outside in a radialdirection of a first coil-end group 31 a and a second coil-end group 31b of the stator 2. The rectifiers 5 are provided at one end of thevehicular AC generator 1 on the opposite side of the pulley. That is,the first coil-end group 31 a is arranged in matching positionalrelationship with these rectifiers 5.

The stator 2 is made up of a stator core 32 formed with slots 35, astator winding composed of a number of electrical conductors such ascopper coils fitted in the slots 35, and insulators 34 inserted betweenthe stator core 32 and the electrical conductors for providingelectrical insulation therebetween. The stator core 32 is fixedly heldbetween the pair of front and rear housings 4 a and 4 b.

FIG. 2 is a partial cross-sectional view of the stator 2, and FIG. 3 isa perspective view illustrating the schematic shape of a segment 33mounted on the stator core 32. As shown in FIG. 2, the stator core 32 isformed with a plurality of slots 35 so as to accommodate a multi-phasestator winding. In this particular embodiment, seventy-two slots 35 arearranged at regular intervals to accommodate a three-phase statorwinding, corresponding to the number of poles in the rotor 3.

The stator winding fitted in the slots 35 of the stator core 32 can beregarded as discrete electrical conductors, and in this regard each ofthe slots 35 contains an even number (four in this embodiment) ofelectrical conductors. These four electrical conductors accommodated inthe single slot 35 are radially aligned from inside toward the outsideof the stator core 32, forming an innermost layer, inner-middle layer,outer-middle layer, and outermost layer. These electrical conductors arecoated with polyamideimide or the like to form an insulation film 37 ontheir surface.

The stator winding is formed by connecting these electrical conductorsin a predetermined pattern. In this embodiment, the electricalconductors accommodated in the slots 35 in radial alignment areelectrically insulated from each other, their ends extending to theoutside of the slots 35. These extending ends, on the side of the firstcoil-end group 31 a, are connected together by being continuous wires,while those on the side of the second coil-end group 31 b are connectedtogether by bonding. One of the electrical conductors in each slot 35makes a pair with one of the electrical conductors in another slot 35that is spaced therefrom at a distance corresponding to a predeterminedpole pitch.

More specifically, an electrical conductor in a predetermined layerwithin one slot 35 makes a pair with an electrical conductor in adifferent layer within a different slot 35 which is at a distancecorresponding to the predetermined pole pitch. This arrangement is forsecuring certain clearances between the plurality of electricalconductors at one coil end while aligning them in a desired pattern. Forexample, the electrical conductor 331 a in the innermost layer of oneslot makes a pair with the electrical conductor 331 b in the outermostlayer of another slot that is spaced by one pole pitch in the clockwisedirection of the stator core 32. Similarly, the electrical conductor 332a in the inner-middle layer of one slot makes a pair with the electricalconductor 332 b in the outer-middle layer of another slot that is spacedby one pole pitch in the clockwise direction of the stator core 32.

These pairs of electrical conductors are connected to each other viacontinuous turn portions 331 c and 332 c formed at one axial end of thestator core 32. Thus at this end of the stator core 32, the continuouswire that connects the electrical conductors of the innermost andoutermost layers circumscribes the continuous wire that connects theelectrical conductors of the inner-middle and outer-middle layers. Inother words, at one end of the stator core 32, the connecting portion ofa pair of electrical conductors is surrounded by the connecting portionof another pair of electrical conductors accommodated in the same slots.The connecting portions of the electrical conductors of the inner-middleand outer-middle layers form an inner layer of the coil end, and theconnecting portions of the electrical conductors of the innermost andoutermost layers form an outer layer of the coil end.

Meanwhile, the electrical conductor 332 a in the inner-middle layer ofone slot also makes a pair with a specific electrical conductor in theinnermost layer of another slot that is spaced away in the clockwisedirection of the stator core 32 by one pole pitch. Similarly, theelectrical conductor 331 b′ in the outermost layer of one slot makes apair with the electrical conductor 332 b in the outer-middle layer ofanother slot that is spaced away in the clockwise direction of thestator core 32 by one pole pitch. These electrical conductors areconnected together by bonding at the other (opposite) axial end of thestator core 32.

Therefore, at the other end of the stator core 32, the bonded portionsconnecting the electrical conductors of the outermost and outer-middlelayers, and the bonded portions connecting the electrical conductors ofinnermost and inner-middle layers, are arranged side by side in theradial direction. These bonded portions of the electrical conductors ofthe outermost and outer-middle layers and those of the innermost andinner-middle layers form adjacent layers of the coil end.

Thus at the other end of the stator core 32, the connecting portions ofthe pairs of electrical conductors are arranged side by side withoutoverlapping each other. Furthermore, these plurality of electricalconductors are made of segments of a predetermined shape having a flatrectangular cross section and a uniform width. As shown in FIG. 3, aU-shaped large segment 331 constitutes the electrical conductors of theinnermost and outermost layers, and a U-shaped small segment 332constitutes the electrical conductors of the inner-middle andouter-middle layers.

One large segment 331 and one small segment 332 make up a basic segment33. The basic segment 33 may be referred to as a “conductor segment” orsimply a “segment” in the following description. These basic segments 33are fitted in the slots 35 in a regular pattern so as to form a two-turnwinding around the stator core 32. The segments for constituting aleading wire of the stator winding and for connecting the first turnwith the second turn of the winding have a different shape from thebasic segments. This embodiment uses three such irregular-shapesegments. The connection between the first turn and second turn of thewinding, where the outer layer and the inner layer of the coil end areconnected, forms an irregular-shape coil end.

Hereinafter, the manufacturing process of the stator winding will bedescribed.

The manufacturing process of the stator 2 includes the steps of: a stepof forming radial indentations in the side faces of each of theconductor segments 331 and 332 by pressing; a step of inserting theconductor segments 331 and 332 in the slots 35 so that they adjoin eachother in the radial direction; a step of bending each of the conductorsegments and the adjacent conductor segments (for example, 331 a and 332a, and 332 b′ and 331 b′) in different circumferential directions(clockwise and counterclockwise) at a predetermined pole pitch anglesuch that the indentations formed in the side faces of the conductorsegments (for example, 331 a and 332 a, and 332 b′ and 331 b′) intersecteach other in a face-to-face relationship; and a step of bonding theends of the conductor segments to the ends of their radially adjoiningconductor segments (for example, 331 d′ and 332 d, and 332 e and 331e′).

In the step of forming indentations, as shown in FIGS. 7A and 7B, a dieis placed on one side (on the opposite side of a straight portion 332 b)of a straight portion 331 b of the conductor segment, and the other sideof the straight portion 331 b (the side facing the straight portion 332b) is pressed by a tapered punch. The punch is tapered in a lateraldirection so that its protrusion in the pressing direction denoted bythe arrow increases gradually towards the end of the straight portion331 b. Thus the formed indentation 331 h has a gradually increasingdepth towards one end.

In the insertion step, basic segments 33 are inserted from one axialside of the stator core 32, such that the turn portion 331 c of theU-shaped large segment circumscribes the turn portion 332 c of theU-shaped small segment 332. One electrical conductor 331 a of the largesegment 331 is inserted into the innermost layer of one of the slots inthe stator core 32, while one electrical conductor 332 a of the smallsegment 332 is inserted into the inner-middle layer of the same slot.The other electrical conductor 331 b of the large segment 331 isinserted into the outermost layer of a different slot that is distancedby one pole pitch from the aforementioned slot in the clockwisedirection of the stator core 32, while the other electrical conductor ofthe small segment 332 is inserted into the outer-middle layer of thissecond slot.

As a result, as shown in FIG. 2, the straight portions 331 a, 332 a, 332b′, and 331 b′ of these electrical conductors are aligned in one slotfrom the innermost layer side toward the outside. The straight portions332 b′ and 331 b′ are of the large and small segments that respectivelymake pairs with electrical conductors in the different (or the second)slot that is spaced by one pole pitch. Since the electrical conductor 33is made of a U-shaped segment, it shows a certain springback in adirection in which the turn portions 331 c, 332 c spread. Accordingly,there is a certain clearance between the straight portions 332 a and 332b of the small segment 332.

In the bending step, after the large and small segments 331 and 332 havebeen inserted, the straight portions 331 a and 331 b positioned at theouter layer of the coil end are bent in a direction in which the largesegment 331 opens out, so that their bonded ends 331 d and 331 e will bepositioned away from each other by a pitch of half a pole (whichcorresponds to one and a half slots in this embodiment). The straightportions 332 a and 332 b positioned at the inner layer of the coil endare bent in a direction in which the small segment 332 closes, so thattheir bonded ends 332 d and 332 e will be positioned closer by a pitchof half a pole. Thus the second coil-end group 31 b is laid out suchthat radially adjacent electrical conductors are bent incircumferentially opposite directions, and radially intersect each otherat one point or more.

The other segments 33 are all fitted likewise in each of the slots 35.

In the bonding step, the bonded ends 331 e′ and 332 e of the outermostand outer-middle layers, and the bonded ends 332 d and 331 d′ of theinner-middle and innermost layers, are respectively bonded together byany of welding, ultrasonic welding, arc welding, or soldering so as toachieve an electrical connection. The resultant stator appears as shownin the perspective view of FIG. 4.

FIG. 5 is a side view of the second coil-end group 31 b viewed from theinside of the stator core 32. FIG. 6 is a diagram illustrating a largesegment and a small segment, and FIG. 7B is an enlarged view of theindentations in FIG. 6. FIG. 8 is a diagram illustrating a large segmentand a small segment according to prior art, and FIG. 9 is an enlargedview of the indentation 331 h in FIG. 8. As shown in FIGS. 6 and 8, thelarge and small segments 331 and 332 are formed with indentations 331 g,331 h, 332 g, and 332 h in their respective straight portions 331 a, 331b, 332 a, and 332 b in the faces opposing each other when the turnportions 331 c and 332 c are aligned with each other in multiple layers.These indentations 331 g, 331 h, 332 g, and 332 h are provided over anarea P that covers intersecting portions 33 c where the radiallyadjacent electrical conductors intersect each other when the segments 33are bent in the circumferential direction after being inserted into theslots 35.

These indentations 331 g, 331 h, 332 g, and 332 h are formed in theopposite side faces of radially adjacent conductor segments over thearea P shown in FIGS. 5 and 6. In other words, the conductor segmentshave a smaller thickness in the area where these indentations 331 g, 331h, 332 g, and 332 h are formed than the radial thickness at either endof the segments 331 and 332. Thus a sufficient clearance is securedbetween each adjacent conductor segment in the area P, which in turnenhances insulation between the conductor segments in the area P at thecoil end where they intersect each other. This improves the coolingefficiency when air passes.

In the prior art conductor segments shown in FIG. 8, the indentations331 g, 331 h, 332 g, and 332 h of the large and small segments 331 and332 are formed parallel to the length of their straight portions 331 a,331 b, 332 a, and 332 b, so that the conductor segments have a uniformthickness in their indentations 331 g, 331 h, 332 g, and 332 h. Incontrast, the indentations 331 g, 331 h, 332 g, and 332 h in thisembodiment are formed such that the thickness of the segments reducestowards the coil end (where the ends of the segments are bondedtogether).

Referring to FIG. 7B, for example, an indentation 331h formed in asegment's straight portion 331 b in this embodiment is typically formedsuch that its depth h1 near the coil end or the end of the conductorsegment is larger than the depth h2 that is away from the coil end, orh1>h2. In other words, the indentations 331 g, 331 h, 332 g, and 332 hare formed to have a gradually increasing depth toward the ends wherethe adjacent conductor segments are bonded together, so that each of theindentations of the segments has a taper shape (the thickness of thesegment is reduced towards the ends).

The principal benefits of providing such a taper in the indentationswill be described below.

FIG. 10 is a cross section taken along the line 11 a-11 a of FIG. 9 insuperposed relation with a cross section taken along the line 11 b-11 bof FIG. 9. The 11 a-11 a cross section shows a cross-sectionalconfiguration of the straight portion of the conductor segment, and the11 b-11 b cross section shows a cross-sectional configuration of theindentation 331 h of the conductor segment. The same is true for 331 g,332 g, and 332 h. The conductor segment before being formed with theindentation 331 h has a rectangular cross section with rounded corners,or a cross section that can be regarded as oval, as shown in FIG. 10.The rounded corners have a radius to an extent that will absorb anydisplacement of the material when the indentation 331 h is formed bypressing. Therefore the width of the conductor segment remains the sameas that shown in FIG. 10 even in the indentations 331 g, 331 h, 332 g,and 332 h. In other words, the relationship between the cross-sectionalareas s1 to s24 indicated by diagonal lines in FIG. 10 can be expressedas follows:s 1=s 21+s 22+s 23+s 24   (Equation 1)

FIGS. 11A and 11B show cross sections of the conductor segment beforeand after forming the indentations. FIG. 11A is a cross section beforeforming the indentations (a cross section taken along the line 11 a-11 aof FIG. 9, and FIG. 11B is a cross section after forming theindentations (a cross section taken along the line 11 b-11 b of FIG. 9.W1 represents the width of the conductor segment, R11 the radius of therounded corners in the rectangular cross section of the conductorsegment before forming the indentation 331 h, and R2 the radius of therounded corners in the rectangular cross section of the conductorsegment after forming the indentation 331 h. As can be seen from FIGS.11A and 11B, the width W1 of the conductor segment remains unchangedbefore and after forming the indentation. That is, the displacement ofthe material which occurs when pressing an indentation of a depth h isabsorbed by the rounded corners becoming sharper, i.e., by the reductionin radius from R11 to R2 at the rounded corners of the rectangular crosssection of the conductor segment.

FIGS. 12A and 12B illustrate a change in the cross-sectionalconfiguration of the conductor segment when forming an indentation in acase in which the conductor segment has a smaller radius R12 than R11 inFIG. 11A at the corners of its rectangular cross section. If theindentation is to be formed to allow the equation 1 to be established,the depth h′ of the indentation will be smaller than the depth h.Therefore, a sufficient clearance will not be secured at theintersecting portions of the conductor segments, and there is the riskof short-circuiting the segments. On the other hand, if the indentationis forcibly formed so that h′=h, the conductor segments could suffer acrack in their insulation film, in which case there is also a high riskof short-circuiting the segments.

Next, FIGS. 13A and 13B illustrate a change in the cross-sectionalconfiguration of the conductor segment when forming an indentation in acase in which the conductor segment has a larger width W2 than W1 inFIG. 11A. If the indentation is to be formed while allowing the equation1 to be established, the depth h″ of the indentation will be smallerthan the depth h′. Therefore, a sufficient clearance will not be securedat the intersecting portions of the conductor segments, and there is therisk of short-circuiting. On the other hand, if the indentation isforcibly formed so that h″=h, the conductor segments could suffer acrack in their insulation films, in which case there is also a high riskof short-circuiting.

As demonstrated above, if the radius at the rounded corners in therectangular cross section of the conductor segment is too small, or ifthe width of the conductor segment is too large, the indentations cannotbe formed with a satisfactory depth for providing sufficient clearancesat the intersecting portions of the conductor segments. The intersectingportions 33 c shown in FIG. 5, particularly near the bonded ends at thecoil end, are susceptible to damage in the insulation films such aspeeling or cracks because of the heat of welding. Accordingly, it isimportant to secure sufficient clearances between the conductor segmentsnear the bonded ends.

In this embodiment, the large and small segments 331 and 332 are formedwith the indentations 331 g, 331 h, 332 g, and 332 h having a reversetaper with their depths increasing towards the segment ends on theopposite side of the turn portions 331 c and 332 c near the segmentends, which will be bonded together, and therefore they are providedwith sufficient clearances near their bonded ends. Further, even if itis difficult to form the indentations with a sufficient depth because ofa small corner radius of the rectangular cross section of the conductorsegments, or because of a large width of the conductor segments, it ispossible to secure satisfactory clearances at intersecting portions ofthe conductor segments near their bonded ends at the coil end whereshort-circuiting is most likely to occur.

Accordingly, vibration of the vehicle will not easily cause radiallyadjacent electrical conductors at the second coil-end group 31 b tocontact each other, and thereby the risk of the insulation film 37 beingdamaged will be reduced. Also, short-circuiting caused by contactsbetween damaged portions of insulation films 37 is prevented.

Further, there are clearances in the radial direction in theintersecting portions 33 c between adjacent conductor segments. Becauseof these, a centrifugal air current having a circumferential componentcreated by inner fans can pass not only through the mesh-like airpassages 36 in the second coil-end group 31 b but also through theradial clearances in the intersecting portions 33 c between theconductor segments. Thus the coil end is cooled much more efficiently.

In the embodiment described above, the indentations 331 g, 331 h, 332 g,and 332 h are provided over the area P that covers the wholeintersecting portions 33 c of the radially adjacent conductor segments.However, they need not necessarily span the entire intersectingportions, and may instead, for example, as shown in FIG. 14, cover onlythe intersecting portions Q near the bonded ends where short-circuitingis most likely to occur.

FIGS. 5 and 14 both show examples in which the conductor segmentsintersect each other at two points, but if there are more than threeintersecting points, the indentations may be provided such as to coverall those three or more intersecting points.

The indentations 331 g, 331 h, 332 g, and 332 h need not necessarily beflat-shaped and may be curved.

Second Embodiment

In a second embodiment of the present invention, even when the adjoiningconductor segments at the coil end cross each other in a twisted state,clearances are secured in the intersecting portions of adjacentconductor segments by forming radial indentations.

The manufacturing process of the stator 2 of the second embodimentincludes: a step of forming indentations in the side faces of each ofthe conductor segments 331 and 332 by pressing, the indentations beingslanted so as to be oriented in the radial direction when the segmentsare twisted; a step of inserting the conductor segments 331 and 332 inthe slots 35 so that they adjoin each other in the radial direction; astep of bending each of the conductor segments and radially adjacentsegments (for example, 331 a and 332 a, and 332 b′ and 331 b′) indifferent circumferential directions at a predetermined pole pitch anglein a twisting fashion such that the indentations formed in the sidefaces of the adjacent conductor segments (for example, 331 a and 332 a,and 332 b′ and 331 b′) intersect each other in a face-to-facerelationship; and a step of bonding the ends of the conductor segmentsto the ends of the radially adjoining conductor segments (for example,331 d′ and 332 d, and 332 e and 331 e′).

In the bending step after the large and small segments 331 and 332 havebeen inserted into the stator core 32, as shown in FIG. 3, the straightportions 331 a and 331 b positioned at the outer layer of the coil endare bent in a direction in which the large segment opens out, so thattheir bonded ends 331 d and 331 e will be positioned away from eachother by a pitch of half a pole (which corresponds to one and a halfslots in this embodiment).

The straight portions 332 a and 332 b positioned at the inner layer ofthe coil end are bent in a direction in which the small segment 332closes, so that their bonded ends 332 d and 332 e are closer to eachother by a pitch of half a pole. Thus the second coil-end group 31 b islaid out such that radially adjacent electrical conductors are bent incircumferentially opposite directions. The large and small segments 331and 332 may be twisted when being bent as described above. How such atwist would occur in the prior art large and small segments 331 and 332will be explained below with reference to FIGS. 15 and 16.

FIG. 15 illustrates large and small segments 331 and 332 of FIG. 3 thatare inserted in the stator core. As described above, after beinginserted into the stator core, the large and small segments 331 and 332are bent in circumferential directions as shown in FIG. 16. At thistime, the large and small segments 331 and 332 are bent incircumferentially opposite directions. Taking one row of bonded ends 331d′, 332 d, 332 e, and 331 e′ as one example, how the large and smallsegments 331 and 332 are twisted will be explained with reference toFIGS. 15 and 16, and FIG. 17, which is a view taken in the direction ofarrow R in FIG. 16.

The ends 331 d′, 332 d, 332 e, and 331 e′ at the coil end of large andsmall segments 331 and 332 are clamped by twisting jigs 36 and movedalong a circular track so that the segments are bent in circumferentialdirection by a pitch of half a pole. The ends of the segments are nottwisted and arranged parallel to each other in single file towards thecenter of the stator. On the other hand, the other parts of the segmentswhich are not clamped by the twisting jigs 36 become twisted as thesegments are bent by a pitch of half a pole, since they are free fromthe grip of the jigs. Thus they are skewed relative to the center of thestator. FIG. 18 is a cross section across the line 18-18 of FIG. 5viewed in the direction of arrow S in FIG. 16. The figure shows how theintersecting portions P of the conductor segments are twisted.

As can be seen from FIG. 18, the innermost and outer-middle layers aretwisted in one direction, while the inner-middle and outermost layersare twisted in the opposite direction, as a result of which the roundedcorners of rectangular cross sections of the conductor segments areabutting the opposing segments. FIGS. 19 and 20 are cross sections,taken similarly to FIG. 18, of bond areas 331 i, 332 i, 331 j, and 332 jof prior art segments provided with indentations 331 g, 331 h, 332 g,and 332 h in the intersecting portions on the same plane as the bondareas of the segments. FIG. 19 illustrates the segments which are nottwisted, and FIG. 20 illustrates those which are twisted. The clearanceC2 between the segments in the intersecting portions when they aretwisted is clearly smaller than the clearance C1 between the segmentswhen they are not twisted. That is, when the segments are twisted,sufficient clearances cannot be secured in the intersecting portions ofthe segments, if the indentations are formed on the same plane as thebond areas. Because of this, the insulation films are more susceptibleto damage, and short-circuiting is more likely to occur.

In the second embodiment, therefore, taking account of the twist in theintersecting portions of the conductor segments, the indentations 331 g,331 h, 332 g, and 332 h are provided as slanted side faces, as shown inFIG. 21, relative to the opposing bond areas of radially adjacentconductor segments. Thus the indentations 331 g, 331 h, 332 g, and 332 hare oriented radially when the conductor segments are twisted, withopposing indentations 331 g and 332 g, and indentations 331 h and 332 hbeing substantially parallel to each other. As a result, the clearanceC3 in the intersecting portions 33 c is much larger than the clearanceC2 shown in FIG. 20. The broken lines in the figure indicate the crosssections of the segments before forming the indentations by pressing.

FIGS. 22 through 24 illustrate the large and small segments 331 and 332of the second embodiment before being twisted. FIG. 22 is a perspectiveview, FIG. 23 is a cross-sectional view taken along the line 23-23 ofFIG. 22, and FIG. 24 is a cross-sectional view taken along the line24-24 of FIG. 22. The broken lines in FIG. 24 indicate the crosssections of the segments before forming the indentations by pressing.

Indentations 331 g, 331 h, 332 g, and 332 h are provided over area P(see FIGS. 5 and 22) to cover intersecting portions 33 c where radiallyadjacent conductor segments 33, after being inserted into the slots 35,intersect each other when they are twisted in the circumferentialdirection. Accordingly, similarly to the first embodiment, sufficientclearances are secured in the intersecting portions of the conductorsegments at the coil end, whereby damage to their insulation films andresulting short circuits are prevented.

In the second embodiment described above, the twist in the conductorsegments is taken into consideration, and so the indentations are formedto be slanted so that they will be oriented radially when the segmentsare twisted after being inserted into the slots 35. Another option is toprovide the indentations on a plane parallel to the bond areas in theindentation formation step as in the first embodiment, and, after thesegments have been twisted in the bending step, to twist back thesegments in an additional step so that the indentations 331 g and 332 g,and 331 h and 332 h will face each other in a substantially parallelrelationship. FIG. 25 is a cross-sectional view of the indentations 331g, 331 h, 332 g, and 332 h in a modified example of the secondembodiment, corresponding to FIG. 24 of the second embodiment. Brokenlines in FIG. 25 indicate the segments before being twisted back in theadditional step. In this modified example of the second embodiment, theclearance C4 in the intersecting portions is made larger than theclearance C2 in FIG. 20, and thus the same effects as those of thesecond embodiment can be expected.

Similar to the first embodiment, the indentations 331 g, 331 h, 332 g,and 332 h need not necessarily span all intersecting portions but maycover only part of the intersecting portions near the ends which will bewelded to other conductor segments where short-circuiting is more likelyto occur. Alternatively, if the segments intersect each other at threeor more intersecting points, the indentations may be formed at the threeor more intersecting points.

The indentations 331 g, 331 h, 332 g, and 332 h need not necessarily beflat-shaped, but may be curved.

Third Embodiment

The distinguishing feature of the third embodiment is that protrusionsare formed at the ends (including the bond areas) of the conductorsegments at the coil end. The protrusions are offset toward the otherconductor segments to be bonded.

FIG. 26 illustrates the large and small segments 331 and 332 in thethird embodiment. The large and small segments 331 and 332 arerespectively formed with protrusions 331 k, 331 l, 332 k, and 332 l onthe faces of the straight portions 331 a, 331 b, 332 a, and 332 b whichface each other when the turn portions 331 c and 332 c are aligned inmultiple layers. FIG. 27 is an enlarged view near the end of the largesegment 331 formed with the protrusion 331 l. The end of the largesegment 331 is protruded, by pressing or the like, toward the side ofthe other conductor segment, to the bond area of which the bond area 331j of the large segment 331 will be bonded. The offset amount h1 of theprotrusion 331 l toward that direction on the side of the bond area isequal to the offset amount h2 on the opposite side. (A like arrangementapplies to protrusions 331 k, 332 k, 332 l).

FIG. 28 is a cross-sectional view taken along the line 28-28 of FIG. 26,and FIG. 29 is a cross-sectional view taken along the line 29-29 of FIG.26. After forming the protrusions 331 k, 331 l, 332 k, and 332 l, thebond areas 331 i and 331 j, and 332 i and 332 j are bonded together,whereby a clearance C4 is provided in advance between the large andsmall segments 331 and 332 as shown in FIG. 28. Thus the same effects asthose of the first and second embodiments described above can beexpected.

When welding the ends of the conductor segments, the bond areas of theconductor segment ends are in contact with each other very tightly.Therefore, in the present embodiment the provision of segment ends thatare offset in mutually approaching directions will also ensure securewelding of the bond areas.

In the embodiment described above, the offset amounts of the protrusions331 k, 331 l, 332 k, and 332 l in opposite directions are identical, butthe same effects will be obtained even if they are different.

In the embodiment described above, the clearances in the intersectingportions between conductor segments are secured by offsetting thesegment ends to be bonded together in mutually approaching directions.Another option, as a modified example of the third embodiment, is shownin FIGS. 30A and 30B. The example involves pressing the end of thestraight portion 331 b that is secured on a die in a directionperpendicular to the longitudinal direction of segment 331 b with apunch as shown in FIG. 30A. This causes bending in the end of thestraight portion 331 b of the segment toward the side of the bond area331 j, so as to form a protrusion 331 l as shown in FIG. 30B thatprotrudes toward the other segment to which it is bonded.

Another Embodiment

The construction of the first or the second embodiment with indentationsin the straight portions of the segments may be combined with theconstruction of the third embodiment provided with protrusions at theends of the conductor segments.

For example, in one such embodiment shown in FIG. 31, the conductorsegments in the innermost and outermost layers 331 a and 331 b′,respectively, have the protrusions of the third embodiment at theirends, while those in the inner-middle and outer-middle layers 332 a and332 b′, respectively, have the indentations of the second embodiment intheir straight portions. The reason why the indentations of the secondembodiment are not employed for the segments in the innermost andoutermost layers 331 a and 331 b′ is as follows. The formation of theindentations of the first or second embodiment causes the corner radiusof the rectangular cross section of the conductor segments to becomesmaller as described above. Therefore, if the indentations of the secondembodiment are provided to the segments for the innermost and outermostlayers 331 a and 331 b′, there is the risk that, when inserting theconductor segments into the slots 35, the relatively sharper corners ofthe conductor segments 331 b′ may be caught in the insulator 34 as shownin the enlarged view of FIG. 32, and the conductor segments may becomecrooked.

In the embodiment shown in FIG. 31, the conductor segments in theinnermost and outermost layers 331 a and 331 b′ are provided only withprotrusions at their ends toward the bonding direction so as to avoidthe reduction in the corner radius of the rectangular cross section ofthe conductor segments, which is brought about by the formation ofindentations. On the other hand, the conductor segments in theinner-middle and outer-middle layers 332 a and 332 b′ are formed withindentations in their straight portions. Thus all the segments can besmoothly inserted into slots 35 without being caught in the insulator34, and at the same time sufficient clearances necessary for preventingshort circuits are provided in the intersecting portions of theconductor segments.

ADVANTAGES OF THE INVENTION

As described above, the stator for the vehicular rotary electric machineas described in the first aspect of the present invention has anindentation formed in a side face of one electrical conductor oppositeto another electrical conductor at their intersecting portion. Since theindentation has a depth gradually increasing towards the end thereof, asufficient clearance is secured between the electrical conductors intheir intersecting portion near the ends, where the insulation films areliable to be damaged by heat at the time of welding. Electricalinsulation is thereby ensured, and the cooling efficiency at the coilend is improved.

According to the stator for the vehicular rotary electric machineaccording to the second aspect, even when one electrical conductor istwisted at the coil end, its radial thickness is kept small. Therefore,a sufficient clearance is secured between the electrical conductors,which ensures electrical insulation while improving the coolingefficiency at the coil end.

According to the stator for the vehicular rotary electric machineaccording to the third aspect of the invention, the radial indentationis formed in its side face that opposes the other one in a skewedfashion. Therefore, even when one electrical conductor is twisted, itsradial thickness is kept small. Accordingly, a sufficient clearance issecured between the electrical conductors, which ensures electricalinsulation while improving the cooling efficiency at the coil end.

According to the stator for the vehicular rotary electric machineaccording to a fourth aspect of the invention, the radial indentation isformed in its side face that is brought substantially parallel in aface-to-face relationship with the side face of the other one bytwisting back the electrical conductor. Accordingly, even when oneelectrical conductor is twisted, its radial thickness is kept small.Therefore, a sufficient clearance is secured between electricalconductors, which ensures electrical insulation while improving thecooling efficiency at the coil end.

According to the stator for the vehicular rotary electric machineaccording to the fifth aspect of the invention, the end of the oneelectrical conductor at the coil end is formed with a protrusionprotruding towards the bond area of the other electrical conductor, sothat the other portions of the one electrical conductor are kept apartfrom the other electrical conductor other than the end to be bonded tothe other electrical conductor to provide a sufficient clearancetherebetween. Electrical insulation is thereby ensured, and the coolingefficiency at the coil end is improved.

According to the stator for the vehicular rotary electric machineaccording to the sixth aspect, since the protrusion is formed byoffsetting the end of the one electrical conductor toward the bond areaof the other electrical conductor by pressing or the like, the end ofelectrical conductor is brought closer to the bond area of the otherelectrical conductor, while the other parts of the electrical conductorsother than the end are kept apart from the other electrical conductor.

According to the stator for the vehicular rotary electric machineaccording to the seventh aspect of the invention, since the protrusionis formed by bending the end of the one electrical conductor toward thebond area of the other electrical conductor by pressing or the like, theend of the one electrical conductor is brought closer to the bond areaof the other electrical conductor. The effect of this is that the otherparts of the electrical conductors, other than the particular end, arekept apart from the other electrical conductor.

According to the stator for the vehicular rotary electric machineaccording to the eighth aspect of the invention, since the oneelectrical conductor accommodated in at least one layer in the slots isformed with a protrusion at its end that includes a bond area to bebonded to the other radially adjacent electrical conductor at the coilend, the electrical conductor protrusion of the one electrical conductorprotruding toward the bond area of the other electrical conductor iskept apart from the other electrical conductor except its end which willbe bonded to the other electrical conductor, so as to provide asufficient clearance therebetween. Electrical insulation is therebyensured, and the cooling efficiency at the coil end is improved.

On the other hand, the one electrical conductor accommodated in at leastone of the other layers in the slots intersects the other radiallyadjacent electrical conductor at the coil end at one point or more andis formed with a radial indentation in its side face opposite to theother electrical conductor at any of its intersecting portions.Therefore, a sufficient clearance is provided between the electricalconductors in the intersecting portion. Electrical insulation is therebyensured, and the cooling efficiency at the coil end is also improved.

According to the stator for the vehicular rotary electric machineaccording to the ninth aspect of the invention, the one electricalconductor in the innermost or outermost layer of the slots is formedwith, at its end, a protrusion protruding towards the other electricalconductor but with no indentations. Indentations cause the edges of theelectrical conductor to become sharper. Therefore, there is no risk ofelectrical conductors being caught in the insulation material and norisk of the conductors becoming crooked when being inserted into theslots. They can thus be smoothly inserted into the slots.

According to the manufacturing method of the stator for the vehicularrotary electric machine according to the tenth aspect of the invention,radially adjoining electrical conductors are formed with indentations intheir side faces such that these indentations cross each other with aface-to-face relationship. Therefore, the radial thickness of theelectrical conductors in their intersecting portions is made smaller,whereby clearances between electrical conductors are readily andreliably secured.

According to the manufacturing method of the stator for the vehicularrotary electric machine according to the eleventh aspect of theinvention, since the indentation formed in the one electrical conductorhas a depth gradually increasing towards the end, a sufficient clearanceis secured between the electrical conductors in the intersecting portionnear the ends. Electrical insulation is thereby ensured, and the coolingefficiency at the coil end is improved. Also, even when the electricalconductor has a small radius in the corners of the rectangular crosssection, or even when the conductor segment has a large width, theindentation is readily and reliably secured with a sufficient depth nearthe end of the electrical conductor.

According to the manufacturing method of the stator for the vehicularrotary electric machine according to the twelfth aspect of theinvention, even when the electrical conductors are twisted, the opposingindentations are made substantially parallel to each other by twistingback the electrical conductors in the intersecting portions.Accordingly, the radial thickness is kept small, and sufficientclearances are secured between electrical conductors at theirintersecting portions.

It should be understood that the present invention is not limited to theembodiments and advantages described above and that variousmodifications may be made without departing from the spirit or scope ofthe invention.

1. A manufacturing method of a stator for a vehicular rotary electricmachine including a stator core having a plurality of slots, and amulti-phase stator winding constructed of a plurality of electricalconductors connected together, said electrical conductors beingaccommodated radially side-by-side within said slots and electricallyinsulated from each other, and having ends extending to an outside ofsaid slots and being bonded together to form a coil end, the methodcomprising: forming an indentation in a radial direction in a side faceof each of the electrical conductors by pressing; inserting saidplurality of electrical conductors in a radially side-by-siderelationship with each other in the slots; bending each of theelectrical conductors and radially adjacent electrical conductors indifferent circumferential directions by a predetermined pole pitch suchthat the indentations formed in respective side faces of the adjacentelectrical conductors pass each other in a face-to-face relationship;and bonding on each of each of said electrical conductors to one end ofthe adjacent electrical conductors.
 2. The manufacturing method of astator for a vehicular rotary electric machine according to claim 1,wherein said indentations have depths and are provided by pressing suchthat the depths increase towards one end of said electrical conductors.3. The manufacturing method of a stator for a vehicular rotary electricmachine according to claim 1, wherein bending includes clamping the endsof the electrical conductors and bending the electrical conductors so asto be twisted, and twisting back said electrical conductors in anopposite direction at said intersecting point between the radiallyadjacent electrical conductors so that the indentations are faced to theindentations of said radially adjacent electrical conductors in asubstantially parallel face-to-face relationship with each other.
 4. Themanufacturing method of a stator for a vehicular rotary electric machineaccording to claim 2, wherein bending includes clamping the ends of theelectrical conductors and bending the electrical conductors so as to betwisted, and twisting back said electrical conductors in an oppositedirection at said intersecting point between the radially adjacentelectrical conductors so that the indentations are faced to theindentations of said radially adjacent electrical conductors in asubstantially parallel face-to-face relationship with each other.